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Conference on
Best Pract ices in Maintenance
Management
May 11th & 12th 2010, Pune India
Speaker: Dinkar Joshi
Designation: Sr Manager ( HOD Maintenance)
Organization: Endurance Technologies Pvt. Ltd.,
Aurangabad
Session Role Of Planned Maintenance In
Implementation Of TPM
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May 11, 2010. “Best Practices in Maintenance Management”Pune 2
Role Of Planned Maintenance In
Implementation Of TPM
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May 11, 2010. “Best Practices in Maintenance Management”Pune 3
What is TPM?
Total Profit Management
…………………Company Survives
Total Production Management
………………… ISO, TQM, JIT, Re-Engineering
Total Perfect Manufacturing
…………………. Loss Elimination
Total Productive Maintenance and Management
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May 11, 2010. “Best Practices in Maintenance Management”Pune 4
By implementing TPM, we get a proper image of
“manufacturing product” in the age of automation and
microelectronics, there by contributing to the
prosperity of enterprises and the happiness of
mankind.
TPM Principles
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May 11, 2010. “Best Practices in Maintenance Management”Pune 5
Through TPM ……
1. We pursue efficient production systems and accomplish the highest
customer satisfaction for quality, cost and delivery term.
2. We accomplish zero-disasters & accidents, zero-defects, and zero
breakdowns to build safe and cheerful workshops.
3. We accomplish zero-disasters and zero-pollution to make life safer and
more pleasant, not only for employees, but also for local residents.
4. We eliminate all losses in the resources and energy to conserve the Earth’s
environment.
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May 11, 2010. “Best Practices in Maintenance Management”Pune 6
CHANGE THE MACHINE.
CHANGE THE MAN.
Basic Concept Of TPM
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May 11, 2010. “Best Practices in Maintenance Management”Pune 7
Obtain Minimum 90% OEE( Overall Equipment Effectiveness )
By Keeping Target For All Losses - ZERO
Operate in a manner, so that there are
no customer complaints.
By Keeping Target of Defects - ZERO
TPM Targets
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May 11, 2010. “Best Practices in Maintenance Management”Pune 8
TPM Targets
Reduce the manufacturing cost
By Keeping target of Losses - ZERO
Achieve 100% success in delivering the goods
as required by the customer.
By Targeting Losses -ZERO
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May 11, 2010. “Best Practices in Maintenance Management”Pune 9
TPM Targets
Maintain a accident free environment.
Target For Accidents - ZERO
Increase the suggestions by 3 times. Develop
Multi-skilled and flexible workers.
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May 11, 2010. “Best Practices in Maintenance Management”Pune 10
Accidents
Breakdown
Defect
Losses
ZERO
TPM Targets
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May 11, 2010. “Best Practices in Maintenance Management”Pune 11
ZERO MEANS ONLY ZERO !!!
ZERO HAS NO TOLERANCE
ZERO DEFECT
ZERO BREAKDOWN
ZERO ACCIDENT
What Is Zero…….
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May 11, 2010. “Best Practices in Maintenance Management”Pune 12
• Just Imagine that if 1% of all the flights crashed.
• Just Imagine that if 1% of all the heart surgeries
failed.
• Just Imagine that if 1% of the buildings collapsed
soon after construction.
Importance Of Zero…….
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May 11, 2010. “Best Practices in Maintenance Management”Pune 13
TPM
I n
d i v i d u a l I m p r o v e m e n t
P l a n n e d
M a i n t e n a n c e
D e v e l o p m e n t m a n a g e m e n t
E d
u c a t i o n & T r a i n i n g
A u t o n o m o u s
M a i n t e n a n c e
Q
u a l i t y M a i n t e n a n c e
T P M i
n O f f i c e s
S a f e t y ,
H e a l t h &
E n v i r o n m e n t
5 S is The Base Of TPM
TPM Pillar Structure
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May 11, 2010. “Best Practices in Maintenance Management”Pune 14
Japanese
Term English Translation Equivalent 'S' term
1S Seiri Organization Sort
2S Seiton Tidiness Systematic
3S Seiso Cleaning Sweep
4S Seiketsu Standardization Standardize
5S Shitsuke Discipline Self - Discipline
Concepts Of 5S
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May 11, 2010. “Best Practices in Maintenance Management”Pune 15
1S- PLASE FOR EVERYTHING, 2S EVERYTHING ON ITS OWN PLACE
BEFORE AFTER
NO FIX LOCATION FIX LOCATION
BENEFIT : REDUCE SEARCHING TIME, REDUCE FATIGUE
Example Of 2S
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May 11, 2010. “Best Practices in Maintenance Management”Pune 16
BEFORE AFTER
NO FIX LOCATION FIX LOCATION
BENEFIT : REDUCE SEARCHING TIME, REDUCE FATIGUE
1S- PLASE FOR EVERYTHING, 2S EVERYTHING ON ITS OWN PLACE
Example Of 2S
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May 11, 2010. “Best Practices in Maintenance Management”Pune 17
BEFORE AFTER
NO FIX LOCATION FIX LOCATION
BENEFIT : REDUCE SEARCHING TIME, REDUCE FATIGUE
1S- PLASE FOR EVERYTHING, 2S EVERYTHING ON ITS OWN PLACE
Example Of 2S
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• Reviewing Business Objective
• Loss Structure
• Target setting for achieving Business
Objective
• KPI’s for measuring in KRA.
• Implementing Kobetsu Kaizen Themes.
Support PM Pillar
Improved System with
Improved Maintainability
Loss
Elimination
Key Activities
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• Listing / Stratification of Defects.
• QA / 4M / QM / Q Components.
• CBM of Q Components.
•Defect Analysis using different tools.
• Implementing Defect Elimination Projects.
• Sustenance and Reliability Enhancement.
• Reduction of Inspection / Sampling Cost.
• Elimination of Customer Complaint
Support by PM Pillar
• QM Matrix
• Q Components.
• CBM of Q Components for easy
Inspection
Defect
Elimination
Key Activities
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May 11, 2010. “Best Practices in Maintenance Management”Pune 20
• Practicing CLIRT activities during all
steps.
• Practicing tentative standards
• Monitoring & recording abnormalities
using 5 senses
• Countermeasure against source of
contamination
• Reduction in CLIRT time
I Do, I Check,
I Maintain
Key Activities
Support by PM Pillar
deterioration
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• Prevention of Occurrence & Recurrence
of accidents.
• Safety patrol for Identifying Unsafe
Condition & Acts.
• Health Hazard Elimination using tools
such as mapping etc.,
• Reducing Environmental Impacts
Support by PM Pillar Improved & Safe
Working Atmosphere
Zero
Accident /Health hazard
Key Activities
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May 11, 2010. “Best Practices in Maintenance Management”Pune 22
• Skill Assessment
• Identifying Training Needs for achieving
business objective.
• Imparting Training / OJT / External
happenings in the market.
• Review the skill level and if not okay
retrain.
• Continuous Monitoring.
Upgraded Skill level for
achieving Business Objective
Skill /
Knowledge
Improvement
Support by PM Pillar
Key Activities
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May 11, 2010. “Best Practices in Maintenance Management”Pune 23
• Elimination of Administrative Losses by
eliminating Waste activity & Reducing
Non value added activity
• Reducing the manufacturing Cost
through
cost loss approach with KK pillar.
Cost Awareness /
Cost Effective Programs.
OTPM Loss
Elimination
Key Activities
Support by PM Pillar
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May 11, 2010. “Best Practices in Maintenance Management”Pune 24
• Collection & utilization of feed back
Measuring needs for ease of
manufacturing
Developing new product with
minimum losses
Zero breakdown, zero defect, zero
accident by implementation of MP onnew machines/ equipements
Trouble free new
equipment from
day one
Key Activities
Support by PM Pillar
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May 11, 2010. “Best Practices in Maintenance Management”Pune 25
• Activities to prevent deterioration
• Activities to measure deterioration
• Restore deterioration .
•Support to JH
•Skill enhancement of Maintenance
staff.
•Input to DM for MP Kaizens
Zero Failure
Key Activities
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May 11, 2010. “Best Practices in Maintenance Management”Pune 26
Planned Maintenance
Aim : Enhance maintenance efficiency through
1. Accomplishing zero failures and zero defects byactivities to enhance maintenance technology andskills, to expand equipment MTBF and to shortenequipment MTTR.
2. Reducing input by activities to make equipment
maintenance efficient.
Purpose :
Functions of equipment can be
demonstrated satisfactorilywhenever equipment needs them at minimum
cost.
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May 11, 2010. “Best Practices in Maintenance Management”Pune 27
Activity UOM BMCurrent Status End Target
Dec..09 Jan.10 Feb.10
PBreakdown hrs. Hrs 0
Breakdown Occurrences Nos. 0
Q
Defect due to PM No. of
Phenomenon
0
C
Maintenance Cost Rs./Piece X
Energy Cost
Electricity / Fuel / Water
Rs /piece Y
Spare part Inventory Cost Rs. In Lac Z
S Accident due to weak PM Nos. 0
M
Kaizens No of kaizen /
employee / month
Nos B
Training PM Training Hrs/emp/month V
Planned Maintenance - Targets
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Basic Philosophy of Zero Failure
• Men make equipment fail.
• Equipment can be set for zero-failures provided the thinking
of men change.
• Conventional view of “all equipment can fail” should be
changed to “don’t let equipment fail.”“failures can be reduced to zero.”
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Rules for Zero Failure
Discover latent defects to prevent failures.
Failure
• Dust, Soiling, adhesion of raw
materials.
• Abrasion, backlash, looseness, leaks
• Corrosion, deformation, flaws, cracks• Temperature, vibration, sound and other
errors
“Failure” is only the tip of the iceberg.
Latent defects
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May 11, 2010. “Best Practices in Maintenance Management”Pune 30
Study of past Equipment History
Ranking of Equipment
Support to JH
Preparation of JH3 tent. Stds. and TBM
Equip. Failure Analysis to identify Root Cause
Counter Measures and Kaizens
Sustenance Activities
Predictive Maintenance (CBM)Periodic Maintenance (TBM)
Lubrication & Spare Parts Management
Enhancement of Knowledge & Skill of Maintenance Operators
PM Pillar Methodology
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Equipment Ranking
A : High Priority Equipment or M/C
Most Critical m/c
B : Medium Priority Equipment or M/C
C : Least Priority Equipment or M/C
Ranking of m/c sub parts are done in the same
way.
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Equipment Rating
AREA ITEM Evaluation EvaluationStandard
1. Howoften is the Equipment used? 4 2 1 80%or above : 4
60 to 79 % : 2
59%or below: 12. Is there backup equipment? 5 4 2 1
No (or) Yes, but it takes too many manhours: 5
Available at other plants : 4
Covered by stock : 2
Backup Equipment exists : 1
3. Howhigh is the dedication?
(Proportion of products of a similar type produced by theequipment)
4 2 1 100 ~75%: 4
35 ~75% : 2
0 ~35% : 1
Production
4. To what extend will a failure effect other processes? 5 4 2 1 Affects the entire plant : 5
Affects other processes : 4
Only affects to this m/c : 1
5. Value of monthly scrap losses (Burned rubber, wasted cloth, wasted production etc)
4 2 1 (Wasted production) (Wasted Cloth)
Over Rs. 50000 : 4 Over 2.5 Lakhs : 4
25000 ~50000 : 2 1 Lakh ~2.5lakh : 2
Under 25000 : 1 Under 1 Lakh : 1
Quality
6. Howwill the process run on this equipment affect the
Quality of the finished product?
5 4 2 1 Decisively : 5, 4
Somewhat : 2 Not Significantly : 1
7. Frequency of failures in terms of cost of monthly repairs? 4 2 1
Over Rs. 5000 : 4 Under Rs. 3000 : 1 Rs. 3000 ~5000 : 2
Maintenance Cost
8. Mean Time To Repair? (MTTR) 4 2 1 Over 3 Hours : 4 Under 1 Hour : 1
1 ~3 Hours : 2
Safety 9. To what extent does a failure affect the work environment? (like noise, fumes, dust etc)
5 4 2 1 Can be life threatening : 5
Stops work : 4 No Significant effect: 1
A: Priority Ranked: >30 points B: Semi ranked: 20 ~30 points C(Least Significant ) :
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Machine Ranking
34%
53%
A
B
C
Sr. Cat Specification % contribution Nos.
1 A Critical 34% 27
2 B Moderate 53% 42
3 C Non critical 13% 10
Total machines 79
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Pune
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Support & Guidance to JH Activity
JH - Step 1
JH Step 2
JH Step 3
JH Step 4
JH Step 5
JH Step 6
JH Step 7
RED TAG STRATEGY SUPPORT (1, 2)
COUNTER MEASURES AGAINST SOURCES
Ex-terminate 4 vices (DIRT, RUST, HEAT, VIB)
SUPPORT FOR MAKING STANDARDS OF
CLEANING, LUBRICATION & INSPECTION
EDUCATION OF OVERALL INSPECTION
FOR LEADER
TRAINING TO IMPROVE MAINT RELATED
TECHNICAL ABILITY
STANDARDIZATION
Autonomous PDCA (CAPD)
1. RED Tag summary sheet andRED Tag plan
2. RED Tag improvement plan
Maintaining visuals
controls and displaying
labels, Types of oils etc.
Use WHY-WHY-WHY
From WHY WHY to
SO WHAT - SO WHAT
M
A
I
N
T
H
E
L
P
PRODUCTION
SHOULD BEABLE TO DO THESE
ACTIVITIES
WITHOUT HELP
OF MAINT, PM
GROUP
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Pune
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Countermeasures for Zero Failures
1. Establish basic conditions. Kobetsu Kaizen
2. Keep operating conditions. Jishu Hozen
3. Restore the deterioration. Planned Maintenance
4. Improve weak points in design. Education & Training
5. Improve the skill level. Development Mgmt.
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Data collection for breakdowns
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WHY - WHY Analysis
Oil leaks from cylinder rod each time it operates
Question
ANSWER ACTIONWHY
O-ring changed
What is your final action ?
Answer
Replacing the O-ring
After replacing O-ring, is it OK Yes
Why did you replace O-
ringO-ring cut
Scratch removedWhy O-ring out Rod has scratch
Measures taken to prevent chips
from scattering
Why rod has scratch Chips were scattered and
attached to rod
Cylinder’s position changed and
cover fixed
Why chips were
attached to rod
Cylinder located within scattering
range of chips and rod cover is
not placed
Standardise design and installationWhy cylinder locatedwithin scattering range of
chips and rod cover not
replaced
Defective design and installation
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Pune
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Mechanical,
55
Electrical, 25
Electronics,
14
Mechanical Electrical Electronics
Area wise Stratification of Phenomena's
Total Phenomenon:94
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51
32
18
72
3641
63
19
20
121018
22
Fixture and seat check
High Pressure coolant System
Hydraulic System
Auto Tool Changer
Axis
Rubber sheet
Coolant
Spindle
Table
Lubrication
Air leakage
Burr
Door
Mechanical Area wise Occurrences
Total : 414 Nos.
May 11, 2010.“Best Practices in Maintenance Management”
Pune
C t f Z b kd (M h i l)
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Kaizen, 39Training, 17
CBM, 1
Preventive
Maintenance,
46
No root
cause, 8
Countermeasure for Zero breakdown (Mechanical)
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Pune
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Development of PM module
Step1
2
3
4
5
6
7
Support & Guidance to JH Activities
Evaluate Equipment and
Understand Current Condition
Restore forced & natural deterioration
and Correct weaknesses
Build an Information management System
Maintain flow of breakdown Analysis
Build a Periodic Maintenance System
Build a Predictive Maintenance System
Evaluate the Planned Maintenance System
MP
CM
PM
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Pune
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Normal Operation
Preventive
Maintenance
Proper Operation
Set-up and adjustment
Daily Maintenance
Lubrication
Retightening
Cleaning, Address Latent Defects
Operation Condition, Daily Inspection forDeterioration
Minor Check
Time – based Inspection
Time – based Check
Time – based Inspection
Trend Check
Unscheduled Check
Corrective
Maintenance
(Reliability)
Corrective
Maintenance
(Maintain-ability)
Others
Strength KAIZEN
Lightening of Loading
Accuracy Improvement
Conditions Monitoring
MP Activities
Planned Breakdown Maintenance
Emergency Maintenance
Maintenance
Prevention
Breakdown
Maintenance
Sporadic Repair
Earlier discovery of interior situation and
positive and rapid report/remedy
Corrective
Maintenance
Maintena
nceOperation
RestorationMeasurementPrevention
AssignedImplementation
Classification
KAIZEN Of Check Operation
Check Quality KAIZEN
ProductiveMaintenance
Time based
Maintenance
Predictive
Maintenance
KAIZEN of Check Operation
Roles of PM and JH
May 11, 2010.“Best Practices in Maintenance Management”
Pune
M hi t t
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Spares Parts management
A. Inventory Reduction
1) 1S and 2S Activities
2) TBM based procurement
B. Cost Saving Activities
1) Develop alternative source
2) In house manufacturing & repairs
3) Re use after modification
4) Life enhancement
3) Procurement Lead time reduction
4) Procurement of consumable spare
through schedule agreement route
Machinery spares parts management
6-26May 11, 2010.“Best Practices in Maintenance Management”
Pune
Mp Sheet Generation System
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Mp Sheet Generation System
May 11, 2010.“Best Practices in Maintenance Management”
Pune
Break Down Hrs Status (Press shop)
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Break Down Hrs Status (Press shop)
1200
0
9 0 4
7 2 3
6 6 0
6 2 2
6
1 1
5 4 0
4 2 5
5 5 2
3 0 0
3 0 5
2 8 4
2 4 4
2 1 0
1 1 2
4 2 5
0
300
600
900
1200
1500
1800
B.M. Apr-
07
May-
07
Jun-
07
Jul-07 Aug-
07
Sep-
07
Oct-
07
Nov-
07
Dec-
07
Jan-
08
Feb-
08
Mar-
08
Apr-
08
May-
08
Jun-
08
Tgt
N o s o f H o u r s
BETTER
( Oct-06 to Mar-07 )
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Pune
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Maintenance Cost
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Maintenance Cost
2.1
1.6
1.2
0
1
2
3
4
B.M. Tgt Actual Jun 08
P e r c e n
t a g e
o f s a l e s
BETTER
Maintenance Cost Loss reduction Kaizen done 132 Nos
33 % DOWN
May 11, 2010.“Best Practices in Maintenance Management”
Pune
Defects classification
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Defects classification
A - Type defect B - Type defect C - Type defect
OK
OK
NOT OK
Action
taken byoperator
OK
OK
NOT OK
No action
by operator
LSL USLLSL USL
OK
OK
NOT OK
Action
taken by
operator
LSL USL
• The output is (OK) initially
• Becomes (NG)
• Corrective action is taken
by operator
• Becomes (OK)
• Use Why – Why Analysis
• The output is (OK) initially
• Becomes (NG)
• No action taken by
operator
• Becomes (OK)
• Use PM Analysis
• The output is (NG) initially
• Action taken by operator
• Becomes (OK)
(setting scrap)
May 11, 2010.“Best Practices in Maintenance Management”
Pune
KAIZEN EYE
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KAIZEN EYE
7. Short
8. Can detect
9. Easy
4. Less Bolts
5. No coolant
6. Small
7. Long8. Cannot detect
9. Difficult
4. Many Bolts5. Coolant
6. Big
INCREASE PRODUCTION REDUCE COSTBENEFIT
REDUCE REDUCE ELIMINATE PREVENT INCREASE LIFE
TIME FREQUENCY
RESULT
PROVIDING / CHANGINGCOUNTERMEASURE(Kaizen)
1. Poka Yoke
2. More Friction
3. Partly
IDEA
(OPPOSITE OF ROOT
CAUSE)
1. Poka2. Less Friction
3. Fully
ANALYSIS (ROOTCAUSE)
CORRECT OBSERVATIONPROBLEM (PRESENT
STATUS)
REDUCE / ELIMINATE / INCREASE / PREVENTTHEME
WHEN Trend Continuous, discontinuous, very rare
Time, period Start-up, season, (summer, winter, rainy season), setupWHO Men Day shift, night shift, new employees, temporary help
WHAT Materials Lots, type No.
WHERE Location Part, range, process, equipment
WHICH Trend Direction (+, -, fore, rear, left and right), increase, reduction
HOW Status Equipment, jigs,tools, accuracy (dynamic, stationary), machining conditions
P h e n o m e n a
s t r a t i f i e d
b y 5 W a n d 1 H
May 11, 2010. “Best Practices in Maintenance Management”Pune
Activity KK JH QM PM SH OTPM DM ET
Result Area P Q C D S M
Kaizen Idea Sheet
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Result Area P Q C D S M
Defect Type
Shop: M/C: Reg. No: 2
Kaizen Theme:To reduce setting time for doorspeed .
Kaizen Idea: Easy to Access
Problem/Present Status: On FRDmachine for door speed setting timeis more
Bench Mark 30 MinTarget 5 Min
Kaizen Start 2/11/09
Kaizen Finish 3/11/09
Team Members:1)Mr.K.O.Zanwar.
2)Mr.A.S.Joshi.
3)Mr.B.k.kachke
Benefits:
1)Machine availability improved.Analysis: Result: Door speed setting time
reduced
Root cause : Hard to access
Kaizen Idea Sheet
Why1: Door speed Setting time more
Why2: Guard has to removed forsetting.
Why3: Hard to access
Countermeasure: Provided thewindow cut out on guard for air flowsetting.
How to Sustain : Irreversible
No M/C
T/date Res. Status
1 6 12.11.
09
ASJ Comp.
Scope and Plan for HD30
5
0
50
100
,Nov 09 ' Dec-09
T i m e i n M i n .
Windowfor air flowsetting
Door cylinder
Door cylinder
No window cut out
Case study
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Cost Loss Tree
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REPAIR & MAINTLABOUR
VARIABLE
MFG SUPPORT
MANUFACTURING COST
FIXED
PERSONEL WELFARE ADMIN COST&
PROF FEE
LOL OMLR/W
HRS
B/DCONS
UM
KK KK QM PM PM
GAP GAP GAP
RATE, TAXES,
INSURANCE
BUILDING SPARES DEPRECIA-TION
May 11, 2010. “Best Practices in Maintenance Management”Pune
Cost Loss Tree
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TPM One Point Lesson No.
Date of
preparation.
Engr. Mgr. Prepared By
Theme
Classif icat ion Basic
Knowledge
Improvement
classes
Trouble
class
DATE EXECUTED
TEACHER
STUDENT
Related to CLEAN LUBRICATE INSPECT RETIGHTEN P.M.
METHOD OF USING ALLEN KEY
MK PV Pati l MKP
23-July-08
METHOD OF USING ALLEN KEY
Correct method -
Allen key is fu l ly inserted in the sock et before
t ighten or loosen the bolt .
Wrong method -
Allen key is part ial ly inserted in the sock et
before t ighten or loo sen the bolt .
Allen keyAllen key
May 11, 2010.
“Best Practices in Maintenance Management”
Pune
Planned Maintenance
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Planned MaintenanceKey Activities
Life Extension 1
JH
DETERIORATION
FORCED
DETERIORATION
LIMITING
CONDITION
C
B
M
TIME
J. HOZEN
STEP(4) (6)
ELIMINATION
OF FORCED
DETERIORATION
RESTORATION OF
BASIC CONDITION
REDUCTION
IN SPORADIC
FAILURES
RELIABILITYBASED
MAINT.
DIAGNOSTIC
TECHNIQUE
+ SERVICE LIFE
PREDICTION
J. HOZENEXTENTION OF WORKING LIFE
(IMP.OF WK.PTS OF DESIGN)& ELIMI-NATION OF CHRONIC PROBLEMS
MP DESIGN + INITIAL CONTROLQ.M
PM
KAIZEN KOBETSU KAIZENEDUCATION + TRAINING
SHE
Life Extension 2
[CM]
T
BM
1
T
BM
2
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Planned Maintenance
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May 11, 2010.
“Best Practices in Maintenance Management”
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Planned Maintenance
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